brochure - Fonderie Pandolfo

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Where technology makes the difference.
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__ Benefits for you, benefits for your customers.
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__ How our billets are made.
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__ Customised billets: our billets made to your designs.
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__ Quality processes, quality products.
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__ Environmentally friendly technology.
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__ A new company with forty years of experience.
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Benefits for you.
Benefits for your customers.
Te chnical sp e ci fi cati ons
__billet lengths up to 8 metres with a tolerance of ± 10 mm
__diameters: Ø 178 mm / Ø 203 mm / Ø 228 mm / Ø 254 mm
Ø 279 mm / Ø 305 mm
__billet end squareness of ± 0.5° or better
__straightness error less than 3 mm/m and 15 mm/total length
__metallographic structure suitable for high speed extrusion
__zero inclusions, porosity, cracks and surface defects
__material traceable throughout the whole process;
basic characteristics printed on each billet
__all shipments accompanied by a 3.1 inspection certificate according
to EN 10204:2004
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How our billets are made.
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Preparing the charge
Raw material is held in a storage area comprising a 5,000
m2 warehouse and a 10,000 m2 yard.
This large storage area allows us to separate incoming
materials according to:
___type of alloy
___dimensions
___origin
Scrap material is transported to the charging machine
by a wheeled loader equipped with the latest on-board
weighing system.
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The charging machine
Our charging machine automatically charges aluminium
scrap into the cold chamber of the melting furnace in a
way that minimises heat loss and fume emissions into the
working environment.
Charge capacity is around 4 tons of material.
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The twin chamber melting furnace
Our TCF (Twin Chamber Furnace) holds up to 90 tons
of molten metal and is capable of melting even waste
and scrap that contains paints, plastic parts, oil and paper
without any pre-treatment and without the addition of salts.
The furnace is equipped with a post-combustion and
comburent air pre-heating system to minimise energy
consumption.
Homogeneity of the molten metal is guaranteed by an
electromagnetic pump circulation system.
The molten metal reaches a temperature of around 750°C
in the melting furnace.
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The holding furnace
The chemical composition of the desired alloy is
perfected in the holding furnace. A sophisticated
electronic control system ensures that liquid metal flows
into the casting machine in complete safety.
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Degassing and filtering
Degassing is an important stage in the treatment of the
liquid metal.
The aluminium is purified by insufflating argon and chlorine
to eliminate the hydrogen, oxides and non-metallic
impurities normally responsible for porosity and inclusions
in the finished product.
Next, the liquid metal is passed through a ceramic filter that
offers significant benefits to the aluminium billet production
and finishing process and ensures a top quality finished
product.
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The casting machine
Fonderie Pandolfo uses a WAGSTAFF HOT TOP AIRSLIP
casting machine with 3 casting beds capable of forming billets
of 178, 203, 228, 254, 279 and 305 mm in diameter.
Samples are taken and analysed during the process to certify
the chemical composition of every single casting.
Fonderie Pandolfo can supply billets of up to 8 metres net
length.
Our casting machine can produce over 300 tons of billets a
day in 6 different diameters:
Ø 178 mm = 70 billets per casting
Ø 203 mm = 54 billets per casting
Ø 228 mm = 42 billets per casting
Ø 254 mm = 34 billets per casting
Ø 279 mm = 34 billets per casting
Ø 305 mm = 34 billets per casting
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Ultrasonic inspection, cutting and homogenising
After casting, all billets are subjected to ultrasonic inspection
over their entire length and cross section to ensure perfect
integrity. At this point, the ends are cut off and a sample
taken for analysis in order to guarantee the quality of that
particular casting.
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The billets are then transferred to a continuous
homogenising oven in which they are thermally treated to
improve workability.
Each individual billet is marked to identify its origin, casting,
serial number and alloy composition.
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Certified billets
Fonderie Pandolfo produces 6000 and 3000 series aluminium
billets conforming to UNI EN 486:2009 “Aluminium and
aluminium alloys. Extrusion ingots. Specifications”.
Each individual billet is tested for chemical composition to ensure
its conformity to the requirements of UNI EN 573-3:2009,
“Aluminium and aluminium alloys. Chemical composition and
form of wrought products - Part 3: Chemical composition and
form of products”.
The traceability of each casting is guaranteed throughout the
entire process.
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CHEMICAL COMPOSITION OF OUR PRINCIPAL ALLOYS
Fonderie
EN573-3:2009
% by weight Pandolfo
designation
Xx elements important for functional purposes
designation
Yy elements important for conformity to heavy metal directives
Impurities
6060
EN AW-6060
Si
Fe
Cu
Mn
Mg
Cr
Zn
Ti
Note
Pb
Hg
Cd
Each
Total
0,30
0,10
0,10
0,10
0,35
0,05
0,15
0,1
0,005
0,01
0,01
0,05
0,15
0,60
0,30
0,05
0,05
0,1
0,005
0,01
0,01
0,05
0,15
0,09
0,005
Mn+Cr
0,005
0,01
0,01
0,04
0,12
0,05
0,12÷0,50
0,005
0,01
0,01
0,05
0,15
0,1
0,005
0,01
0,01
0,05
0,15
0,1
0,005
0,01
0,01
0,05
0,15
0,60
606363
EN AW-6063
0,55
0,15
EN AW-6060
0,60
0,25
0,50
600543
EN AW-6005A
0,05
0,05
0,45
0,67
0,15
0,15
0,10
0,47
0,02
0,73
0,25
0,20
0,15
0,53
0,05
608267
1,00
0,15
0,10
0,46
0,64
0,09
1,10
0,30
0,54
0,72
0,14
606023
0,40
0,15
0,05
0,40
0,05
0,45
0,25
EN AW-6082
EN AW-6060
606045
EN AW-6060
0,05
0,45
0,15
0,50
0,28
0,05
0,05
0,09
0,05
0,005
0,05
0,45
0,45
0,05
0,07
0,50
Note:
Pb, Hg and Cd content
conforms to the requirements
of Directive 2011/65/EU
(R.O.H.S.)
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Customised billets:
our billets made to your designs.
Customised billets.
In addition to our standard products, which conform rigorously to UNI standards, Fonderie Pandolfo can also supply
“customised” billets to satisfy special extrusion requirements.
Our highly qualified staff and forty years of experience enable us to assist customers in all stages of billet
specification and production, from choice of alloy to the calculation of the quantities needed to manufacture a
unique end product that conforms to applicable standards.
Fonderie Pandolfo can also provide a raw material conversion service and handle all aspects of logistics to ensure
maximum speed and flexibility in deliveries.
We only give you the best
Fonderie Pandolfo supplies customers with the best part of every billet.
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Quality processes, quality products.
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High-tech billets
Fonderie Pandolfo’s Maniago plant is rightly proud of its top quality aluminium billets, produced by
high-tech plant and environmentally friendly processes.
Our company applies the strictest quality and environment management systems. To ensure maximum efficiency
and consistent product quality, Fonderie Pandolfo has obtained certification to UNI EN ISO 9001:2008.
Fonderie Pandolfo also implements an occupational health and safety system certified to UNI-INAIL 2003
guidelines.
Environmental protection and intelligent use of our planet’s limited resources are guaranteed by a management
system for which ISO 14001 certification has already been requested.
Our plant has a production capacity of 210 tons of billets a day, equivalent to an annual output of over 70,000
tons.
Fonderie Pandolfo can provide specialist technical assistance to help customers identify the most suitable billet
for their needs.
All our processes are supported by SAP ERP software to guarantee data accuracy and security.
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Environmentally friendly technology.
Noble and eternally renewable
Aluminium is a totally renewable material.
Using aluminium makes more sense than ever today.
Aluminium has always been recognised not only for its light weight, strength and malleability,
but for its re-usability and environmental sustainability too.
It costs less than 1 kW-h of energy to produce 1 kg of ready-to-use aluminium from scrap,
compared to 13 or 14 kW-h to extract it from bauxite.
Aluminium is potentially everlasting: it can be indefinitely and completely recycled,
without any loss of its intrinsic properties.
A clean process
Fonderie Pandolfo melts down aluminium scrap in a high-tech process that respects the highest
standards of environmental safety.
Our furnace is equipped with a post-combustion and fume regeneration system to minimise heat
loss, emissions and energy consumption.
Our sophisticated treatment system continuously monitors and controls emissions to ensure
conformity to the strictest Italian and European environmental legislation.
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Casting. Green for us, green for our customers.
Our production plant is specially designed to minimise use of primary resources
(methane, electricity and water) by applying the latest post-combustion and water
treatment and recovery systems.
Our billets satisfy the requirements of the L.E.E.D.
(Leadership in Energy and Environmental Design) certification
system for “low environmental impact” extruded products for the building
industry.
Originally developed in the United States in the 1990s, the L.E.E.D. certification
system has recently been adopted in Europe too.
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A new company,
with 40 years of experience.
Registered offices and administration
Via della Provvidenza, 143
35030 Rubano (Padua) - Italy
www.fonderiepandolfo.com
[email protected]
Plant
Via Ponte Giulio, 45
33085 Maniago (Pordenone) - Italy
Tel. +39 0427 570100
Fax +39 0427 570141
www.fonderiepandolfo.com
[email protected]
Layout and Graphics Bordieri & Partners • Photo Marco Rossato - Fototipi • Printing Litocenter srl Piazzola sul Brenta PD
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